Apertured polymeric film webs and absorbent articles using such webs

ABSTRACT

The present invention pertains to an apertured polymeric film web material provided with a multiplicity of substantially three dimensional surface structures and provided with a multiplicity of fluid transport apertures. In one embodiment, the fluid transport apertures are formed using a process that substantially preserves the integrity of the surface structures. Methods of producing webs are also disclosed. The present invention also includes multi-ply composite structures formed using apertured polymeric film web materials and a sub-ply. The present invention also pertains to absorbent articles which preferably include a topsheet in accordance with the present invention, a backsheet secured to the topsheet, and an absorbent core positioned between the topsheet and the backsheet.

FIELD OF THE INVENTION

[0001] The present invention relates to an apertured polymeric film webexhibiting a soft and silky tactile impression on at least one of itssurfaces. The present invention also relates to absorbent articlesincorporating a topsheet comprised of a web according to the presentinvention.

BACKGROUND OF THE INVENTION

[0002] It has long been known in the field of disposable absorbentarticles that it is extremely desirable to construct absorptive devices,such as disposable diapers, sanitary napkins, incontinent briefs,bandages, wound dressings, and the like, presenting a soft, silky,cloth-like surface feel to the user to improve wearing comfort andconfidence.

[0003] One solution to the aforementioned problem has been to utilize acovering or topsheet on the exposed, wearer-contacting layer whichcomprises a web of formed, apertured thermoplastic film. Commonlyassigned U.S. Pat. No. 4,342,314, issued to Radel et al. on Aug. 3,1982, the disclosure of which is hereby incorporated herein byreference, discloses a representative formed film of this variety. Inorder to address consumer concerns with regard to plastic-likeappearance and feel, webs of this variety have been developed whichinclude an interconnected structure of fiber-like appearance in theinterest of generating a more cloth-like, aesthetically-pleasingappearance. In addition, apertured, formed thermoplastic film webs havebeen developed which further include microscopic surface texturing(microtexture) and/or microscopic apertures (microapertures) to furtherenhance the visual and tactile impression of such webs. Representativefilm webs of this variety are disclosed in commonly assigned U.S. Pat.No. 4,463,045, issued to Ahr et al. on Jul. 31, 1984, U.S. Pat. No.4,629,643, issued Dec. 16, 1986 to Curro et al., and U.S. Pat. No.4,609,518, issued Sep. 2, 1986 to Curro et al., the disclosures of whichare hereby incorporated herein by reference.

[0004] Another solution has been to utilize a fibrous material as acovering or topsheet on such articles, alone or as an overlay orlaminate over other materials. A representative topsheet structure ofthis variety is disclosed in Statutory Invention Registration H1670published in the name of Aziz et al. on Jul. 1, 1997, the disclosure ofwhich is hereby incorporated herein by reference. Such fibrous materialsmay take the form of a woven or nonwoven web of a suitable fibervariety, and may or may not include discretely formed apertures inaddition to the inherent porosity of the web itself. Such fibrous websexhibit an aesthetically-pleasing, cloth-like surface appearance andtactile impression due to the fibrous nature of the surface.

[0005] While fibrous webs tend to have more cloth-like aesthetics thanfilm webs they also tend to retain fluid in the fiber intersticesresulting in a wet topsheet versus films. What is needed then is afilm-based web that has fibrous web-like aesthetics. The aforementionedCurro et al. patent makes some progress towards this end compared to theaforementioned Radel et al., but does not make a film web nearly as softas the present invention.

SUMMARY OF THE INVENTION

[0006] The present invention meets the needs described above. A novelpolymeric film web that enhances softness and silkiness is describedbelow.

[0007] The present invention pertains to an apertured polymeric film webprovided with a multiplicity of substantially three dimensional surfacestructures on at least one of the web's surfaces and provided with amultiplicity of fluid transport apertures. The web material shallexhibit a soft and silky tactile impression on at least one of itssurfaces such that it has a softness index greater than about 35 and/ora compressibility index greater than about 25 percent.

[0008] Further embodiments of the present invention include utilizingunique combinations of processes to provide the polymeric film web withthree dimensional surface structures and fluid transport apertures.

[0009] A still further embodiment of the present invention is amulti-ply composite structure. The multi-ply composite structure iscomprised of at least two ply: a fluid permeable thermoplastic formedfilm ply having a body facing surface and a garment facing surface and afluid permeable sub-ply. The thermoplastic formed film ply can becomprised of web material as claimed herein and the sub-ply is adjacentto the garment facing surface of the thermoplastic formed web ply.

[0010] Still further embodiments of the present invention may includemulti-ply composite structures comprised of materials with varyingdegrees of permeability. In such embodiments, fluid transport aperturesare provided to form fluid pathways common to all ply.

[0011] Still further embodiments of the present invention may includeany number of layers. In addition, the intermediate layer or layers maycomprise any thermoplastic material. Any number of intermediate layersmay be utilized in forming the thermoplastic formed web plies of thepresent invention.

[0012] The web material of the present invention provides manyadvantages. The unique combination of manufacturing processes selectedand materials used results in a polymeric film web that is softer,silkier, and more cloth-like than prior film materials as measured bythe softness index and compressibility index described herein.

[0013] The present invention also pertains to absorbent articles whichpreferably include a topsheet formed from the web material of thepresent invention, a backsheet secured to the topsheet, and an absorbentcore positioned between the topsheet and the backsheet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] While the specification concludes with claims particularlypointing out and distinctly claiming the present invention, it isbelieved that the present invention will be better understood from thefollowing description in conjunction with the accompanying drawings, inwhich like reference numbers identify like elements, and wherein:

[0015]FIG. 1 is a plan view scanning electron micrograph showing oneembodiment of thermoplastic web of the present invention;

[0016]FIG. 2 is an enlarged cross-sectional scanning electron micrographshowing an arrangement of three dimensional surface structures and fluidtransport apertures according to the present invention;

[0017]FIG. 3 is a plan view scanning electron micrograph that shows (1)a web manufactured in a double hydroforming process as known in theprior art and (2) a web manufactured in accordance with the presentinvention;

[0018]FIG. 4 is a tilt view scanning electron micrograph that shows (1)a web manufactured in a double hydroforming process as known in theprior art and (2) a web manufactured in accordance with the presentinvention;

[0019]FIG. 5 is a cross-sectional view scanning electron micrograph thatshows (1) a web manufactured in a double hydroforming process as knownin the prior art and (2) a web manufactured in accordance with thepresent invention; and

[0020]FIG. 6 is a cross-sectional view that shows one embodiment of amulti-ply composite structure according to the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION Definitions

[0021] As used herein, the term “hydrophilic” is used to refer tosurfaces that are wettable by aqueous fluids (e.g., aqueous body fluids)deposited thereon. Hydrophilicity and wettability are typically definedin terms of water contact angle and the surface tension of the fluidsand solid surfaces involved. This is discussed in detail in the AmericanChemical Society publication entitled Contact Angle, Wettability andAdhesion, edited by Robert F. Gould (Copyright 1964), which is herebyincorporated herein by reference. A surface is said to be wetted by afluid (hydrophilic) when the fluid tends to spread spontaneously acrossthe surface as opposed to forming discrete droplets. Conversely, asurface is considered to be “hydrophobic” if the fluid tends to formdiscrete droplets and does not spread spontaneously across the surface.As used herein, a “hydrophilic web or layer” generally has a watercontact angle less than about 50 degrees. As used herein, a “hydrophobicweb or layer” generally has a water contact angle greater than about 50degrees.

[0022] The term “permanently hydrophilic” as used herein refers to a webthat retains its low contact angle over long periods of time or afterexposure to conditions that would otherwise remove surfactants. Such afilm can be comprised of a block copolymer of a polyether and anotherpolymer. Such a composition renders the web permanently hydrophilicthereby giving the web durable wettability without the need forsurfactant treatment.

[0023] The water contact angle depends on surface inhomogeneities (e.g.,chemical and physical properties, such as roughness), contamination,chemical/physical treatment of the solid surface, or composition of thesolid surface, as well as contamination of the water. The surface energyof the solid also influences the water contact angle. As the surfaceenergy of the solid decreases, the water contact angle increases. As thesurface energy of the solid increases, the water contact angledecreases.

[0024] As used herein, the term “gradient” when applied to differencesin surface energy or work of adhesion is intended to describe a changein surface energy or work of adhesion occurring over a measurabledistance. The term “discontinuity” is intended to refer to a type of“gradient” or transition, wherein the change in surface energy occursover an essentially zero distance. Accordingly, as used herein all“discontinuities” fall within the definition of “gradient”.

[0025] Also, as used herein the terms “capillary” and “capillarity” areused to refer to passageways, apertures, pores, or spaces within astructure which are capable of fluid transport in accordance with theprinciples of capillarity generally represented by the Laplace equation(1):

Δp=2 G(cos A)/R  (1)

[0026] where:

[0027] p is the capillary pressure;

[0028] R is the internal radius of the capillary (capillary radius); and

[0029] G is the surface tension of the liquid measured in dyne/cm, and

[0030] A is the liquid-solid water contact angle measured in degrees.

[0031] As noted in Penetration of Fabrics by Emery I. Valko, found inChapter III of Chem. Aftertreat. Text. (1971), pp. 83-113, which ishereby incorporated herein by reference, for A=90°, the cosine of A iszero and there is no capillary pressure. For A>90°, the cosine of A isnegative and the capillary pressure opposes the entry of fluid into thecapillary. For A<90° the cosine of A is positive and the capillarypressure permits spontaneous entry of fluid into the capillary. Also, Rmust be sufficiently small for p to have a meaningful value, since as Rincreases (larger aperture/capillary structure) the capillary pressuredecreases.

[0032] As utilized herein, the term “incompatible” represents the lackof miscibility between two materials such that each phase substantiallyretains its original properties. Example properties include glasstransition temperature or melting point. Another characterization ofincompatible materials is that the strength of the interface issignificantly weaker than the strength of the weakest individual phase(material). Thus, the work of adhesion between the two materials is muchlower than the lowest cohesive energy of either material, and the riskof delamination is high.

[0033] The term “tie layer” refers to any layer in a web ply that iscomprised of material that serves to tie or join two incompatiblematerials.

[0034] The term “topsheet” generally refers to the cover layer, in anabsorbent article such as a diaper or catamenial pad, that faces thewearer of the absorbent article. The term “wearer-contacting layer orsurface” as used herein refers to the surface of a topsheet or otherabsorbent article component that is nearest the wearer of the article.The term “garment-facing layer or surface” refers to the surface of atopsheet or other absorbent article component that faces away from thewearer when the component is used in an absorbent article.

[0035] The term “Z-dimension” refers to the dimension orthogonal to thelength and width of the layer, structure or article. The Z-dimensionusually corresponds to the thickness of the layer, structure or article.

[0036] The term “three dimensional surface structure” refers to anythree dimensional structure residing on the web surface that serves toenhance the soft and silky tactile impression of the web. Examples ofsuch structures include but are not limited to the following:aberrations; fibrils; incongruities; cone structures; and apertures.Methods for providing three dimensional surface structures can be brokeninto two groups: 1) apertured methods; and 2) non-apertured methods.

[0037] Apertured methods include but are not limited to the following:vacuum forming, hydroforming, needle punching (solid or hollow),hydrosonics, ultrasonics, and any combination thereof.

[0038] Non-apertured methods include but are not limited to thefollowing: mechanical embossing, flocking, delamination of viscous meltsor optionally delamination of viscous melts from porous surfaces,printed hair, brushing, and any combination thereof.

[0039] The term “fluid transport aperture” refers to any aperture in theweb that serves to transport fluids within the web. Examples of fluidtransport aperturing processes include but are not limited to thefollowing: mechanical embossing; stretch rupturing; vacuum forming;hydroforming; hydrocutting; needle punching (solid or hollow);hydrosonics; ultrasonics; slitting; ring-rolling; structuralelastic-like web; and any combination thereof.

[0040] As utilized herein, the term “fluid passageway” is intended toencompass enclosed or at least partially enclosed structures or channelswhich may communicate fluids. The term fluid passageway is thus intendedto encompass the terms “aperture”, “channel”, “capillary”, as well asother similar terms. The passageways inherent in fluid permeablematerials are another example. Many other examples of fluid passagewaysexist in the art and may be used in the present invention.

[0041] The term “monolayer” refers to a ply that is comprised of asingle layer of material.

[0042] The term “sub-ply” refers to a ply located beneath the bodycontacting ply.

[0043] The term “web” as used herein refers to a structure comprised ofone or more ply.

[0044] The term “layer” as used herein refers to an individual layer orlayers of material that are joined to form a ply.

[0045] The term “ply” as used herein refers to a structure that iscomprised of one or more layers of material.

[0046] The term “surface” as used herein refers to a top or first sideof a layer and/or a bottom or second side of a layer.

[0047] As used herein, the term “softness index” refers to the panelscore unit achieved by a test material in the Panel Softness Testdescribed below.

[0048] As used herein, the term “compressibility index” refers to thepercent compression at 0.2 psi achieved by a test material in theCaliper vs. Z-compression Test described below.

[0049] As used herein, the term “absorbent article” refers to deviceswhich absorb and contain body exudates, and, more specifically, refersto devices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term “disposable” is used herein to describe absorbentarticles which are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use, and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” absorbent article refers to absorbent articles which areformed of separate parts united together to form a coordinated entity sothat they do not require separate manipulative parts like a separateholder and pad.

The Apertured Polymeric Web of the Present Invention

[0050] The apertured polymeric film web of the present invention is aweb material that has been (1) provided with a multiplicity ofsubstantially three dimensional surface structures that cause the webmaterial to exhibit a soft, silky surface to improve the wearer'scomfort and (2) provided with fluid transport apertures for improvedfluid handling.

[0051]FIG. 1 is a plan view scanning electron micrograph of oneembodiment of the formed web and depicts the three dimensional surfacestructures 100 and the fluid transport apertures 110 of the presentinvention web. FIG. 2 depicts an enlarged cross-sectional scanningelectron micrograph along line A-A of FIG. 1 that shows the dimensionalrelationship of the three dimensional surface structures 200 and fluidtransport apertures 210 according to the present invention. The size ofboth the three dimensional surface structures 200 and fluid transportapertures 210 may be varied. However, in a preferred embodiment thethree dimensional surface structures are comprised of microapertureshaving a diameter of about 0.02-0.2 mm, a height of about 0.02-0.2 mm,and fluid transport apertures having a minimum diameter of about 0.05mm. As is well known in the art, smaller fluid transport apertures willrequire apertures comprised of more hydrophilic materials to ensuresufficient fluid management properties.

[0052] FIGS. 3-5 are enlarged scanning electron micrograph depicting theplan view, tilt view, and cross section view of the following: (1) atypical prior art web wherein both three dimensional surface structures300 and fluid transport apertures 310 were developed using hydroformingprocesses; and (2) a typical present invention web wherein the threedimensional surface structures 320 were developed by hydroforming butthe fluid transport apertures 330 were developed by mechanicalaperturing means. A comparison of these scanning electron micrographsreveals that the three dimensional surface structures 320 of the presentinvention as depicted in FIG. 3 are substantially less damaged than thethree dimensional surface structures 310 developed by thedouble-hydroforming processes.

[0053] One aspect of the present invention is a fluid pervious websuitable for use as a topsheet in an absorbent article. In a preferredembodiment, the fluid pervious web of the present invention contains aplurality of microapertures. Although the fluid pervious web of thepresent invention is described herein as a topsheet for use in anabsorbent article, one having ordinary skill in the art would recognizethat the fluid pervious web of the present invention would have otheruses, such as bandages, agricultural coverings, and similar uses whereit is desirable to manage fluid flow through a web or ply.

[0054] Providing the fluid pervious web with fluid transport aperturesprovides the fluid handling properties of the web. In a preferredembodiment of the present invention, fluid transport apertures areprovided to the web using means that leave the three dimensional surfacestructures substantially unaltered relative to their as-made state. In apreferred embodiment of the present invention, fluid transport aperturesare provided by mechanically embossing and stretch rupturing the web asdiscussed below.

Web Material Characteristics

[0055] As described herein above, another aspect of the presentinvention is a topsheet comprising the polymeric film web of the presentinvention. The material selected for the polymeric film web of thepresent invention, and therefore for the topsheet formed therefrom, ispreferably machinable and capable of being formed into a sheet. Sincethe topsheet is to be used in consumer products which contact the humanbody, the material utilized in the polymeric film web and used to formthe topsheet is safe for epidermal or other human contact.

[0056] Examples of acceptable web materials are disclosed in commonlyassigned U.S. Pat. No. 4,463,045, issued to Ahr, et al. on Jul. 31,1984, and U.S. Pat. No. 4,629,643, issued Dec. 16, 1986 to Curro et al.,the disclosures of which are hereby incorporated herein by reference.

[0057] In a preferred embodiment of the present invention, the webmaterial selected creates a surface energy gradient between at least twoof the web surfaces. Whenever the wearer-contacting layer and thegarment-facing layer of the topsheet of the present invention comprisematerials having different layer properties (eg., one of the layers ishydrophobic and the other is hydrophilic), a surface energy gradient iscreated. Surface energy gradients have been found to be useful inpromoting fluid transport. A comprehensive explanation of surface energygradients is described in pending U.S. application Ser. No. 09/344,161filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is herebyincorporated herein by reference.

[0058] In a preferred embodiment of the present invention, the webmaterial used is comprised of hydrophobic and permanently hydrophiliclayers, as described in pending U.S. application Ser. No. 09/344,161filed by Lee, et al. on Jun. 24, 1999, the disclosure of which is herebyincorporated herein by reference.

[0059] The performance properties of the topsheet of the presentinvention may be manipulated depending on the orientation of thehydrophilic layer and the hydrophobic layer in the thermoplastic formedweb ply from which the topsheet is formed. As described above, thethermoplastic formed web ply of the present invention may comprise anynumber of layers. The topsheet may be formed so that thewearer-contacting layer is a hydrophobic layer and the garment-facinglayer is hydrophilic (known as “phobic/philic”), or so that thewearer-contacting layer is hydrophilic and the garment facing layer ishydrophobic (known as “philic/phobic”). In addition, by varying both theorientation of the hydrophilic and hydrophobic layers, many differenttopsheet structures, with different advantageous properties, can beformed according to the present invention.

The Multi-Ply Composite Structure of the Present Invention

[0060] As described above, the highly compressible webs of the presentinvention enhance the soft and silky tactile impression when used astopsheets. However, a consequence of these highly compressible materialsis that the void volume between the topsheet material and the adjacentmaterial is easily lost under in-use pressures. This can have thenegative consequence of poor fluid management. Therefore, by combiningthe webs of the present invention described above with a sub-ply that isrelatively non-compressible, the void volume can be protected and serveto provide better fluid management.

[0061] An alternative topsheet orientation, shown in FIG. 6, includes athermoplastic formed film ply 610 comprised of polymeric film webmaterial exhibiting preferred softness and/or compressibility indices asdescribed herein and a sub-ply 620 to form a multi-ply compositestructure 600.

[0062] The multi-ply composite structure 600 may be formed utilizingvarious combinations of non-apertured and apertured materials withvarying degrees of permeability so long as the multi-ply compositestructure 600 serves to transport fluids through the structure. Inaddition, the materials comprising the multi-ply composite structure 600may be selected such that a surface energy gradient is formed between atleast two exterior surfaces of the structure. In a preferred embodimentof the structure, both ply are provided with fluid transport aperturesthat form fluid pathways common to both ply. In another embodiment, themulti-ply composite structure 600 is formed such that it maintains aprotected void volume during use.

[0063] The sub-ply can be comprised of a variety of different materialsor combinations thereof. Suitable sub-ply materials include 1) aperturedformed webs 2) cloth-like formed webs; 3) nonwovens; 4) wovens; 5)foams; 6) cellulosic webs; and 7) combinations thereof.

[0064] Suitable sub-ply formed films are described in U.S. Pat. No.3,929,135, issued to Thompson on Dec. 30, 1975; U.S. Pat. No. 4,324,246,issued to Mullane, et al. on Apr. 13, 1982; U.S. Pat. No. 4,342,314,issued to Radel, et al. on Aug. 3, 1982; U.S. Pat. No. 4,463,045, issuedto Ahr, et al. on Jul. 31, 1984; and U.S. Pat. No. 5,006,394, issued toBaird on Apr. 9, 1991. One especially preferred formed web is describedin one or more of the above patents and marketed on sanitary napkins bythe Procter & Gamble Company of Cincinnati, Ohio as “DRI-WEAVE”.

[0065] Alternatively, cloth-like formed films may comprise the sub-ply.Such webs have a softer, more cloth-like feel. Cloth-like formed websare developed by providing the web surface with either microapertures(as described above), surface texture (described below), or surfacetreatment (described below), or a combination thereof. The sub-ply mayalso be comprised of any nonwoven or woven material capable oftransporting blood, menses, and/or urine. Other materials not listedherein, but capable of transporting blood, menses, and/or urine, areincluded in the present invention.

[0066] The thermoplastic formed web ply of the present invention mayinclude any number of layers as long as there is a tie layer between anyadjacent layers that comprise incompatible materials. In addition, theintermediate layer or layers may comprise any thermoplastic material aslong as there is a tie layer between any adjacent incompatible layers.Any number of intermediate layers may be utilized in forming thethermoplastic formed web plies of the present invention.

Methods of Making

[0067] The polymeric film web of the present invention may be processedusing conventional procedures for producing multi-layer webs onconventional coextruded web-making equipment. In general, polymers canbe melt processed into webs using either cast or blown web extrusionmethods both of which are described in Plastics Extrusion Technology-2ndEd., by Allan A. Griff (Van Nostrand Reinhold 1976), which is herebyincorporated herein by reference. A cast web is extruded through alinear slot die. Generally, the flat web is cooled on a large movingpolished metal roll (chill roll). It quickly cools, and peels off thefirst roll, passes over one or more auxiliary rolls, then through a setof rubber-coated pull or “haul-off” rolls, and finally to a winder.

[0068] In blown web extrusion the melt is extruded upward through a thinannular die opening. This process is also referred to as tubular webextrusion. Air is introduced through the center of the die to inflatethe tube and causes it to expand. A moving bubble is thus formed whichis held at constant size by simultaneous control of internal airpressure, extrusion rate, and haul-off speed. The tube of web is cooledby air blown through one or more chill rings surrounding the tube. Thetube is next collapsed by drawing it into a flattened frame through apair of pull rolls and into a winder.

[0069] A coextrusion process requires more than one extruder and eithera coextrusion feedblock or a multi-manifold die system or combination ofthe two to achieve the multilayer web structure. U.S. Pat. Nos.4,152,387 and 4,197,069, issued May 1, 1979 and Apr. 8, 1980,respectively, both to Cloeren, which are hereby incorporated herein byreference, disclose the feedblock and multi-manifold die principle ofcoextrusion. Multiple extruders are connected to the feedblock which canemploy moveable flow dividers to proportionally change the geometry ofeach individual flow channel in direct relation to the volume of polymerpassing through the flow channels. The flow channels are designed suchthat, at their point of confluence, the materials flow together at thesame velocities and pressure, minimizing interfacial stress and flowinstabilities. Once the materials are joined in the feedblock, they flowinto a single manifold die as a composite structure. Other examples offeedblock and die systems are disclosed in Extrusion Dies for Plasticsand Rubber, W. Michaeli, Hanser, N.Y., 2nd Ed., 1992, herebyincorporated herein by reference. It may be important in such processesthat the melt viscosities, normal stress differences, and melttemperatures of the material do not differ too greatly. Otherwise, layerencapsulation or flow instabilities may result in the die leading topoor control of layer thickness distribution and defects from non-planarinterfaces (e.g. fish eye) in the multilayer web.

[0070] An alternative to feedblock coextrusion is a multi-manifold orvane die as disclosed in aforementioned U.S. Pat. Nos. 4,152,387 and4,197,069, as well as U.S. Pat. No. 4,533,308, issued Aug. 6, 1985 toCloeren, hereby incorporated herein by reference. Whereas in thefeedblock system melt streams are brought together outside and prior toentering the die body, in a multi-manifold or vane die each melt streamhas its own manifold in the die where the polymers spread independentlyin their respective manifolds. The melt streams are married near the dieexit with each melt stream at full die width. Moveable vanes provideadjustability of the exit of each flow channel in direct proportion tothe volume of material flowing through it, allowing the melts to flowtogether at the same velocity, pressure, and desired width.

[0071] Since the melt flow properties and melt temperatures of polymersvary widely, use of a vane die has several advantages. The die lendsitself toward thermal isolation characteristics wherein polymers ofgreatly differing melt temperatures, for example up to 175°F. (80° C.),can be processed together.

[0072] Each manifold in a vane die can be designed and tailored to aspecific polymer. Thus the flow of each polymer is influenced only bythe design of its manifold, and not forces imposed by other polymers.This allows materials with greatly differing melt viscosities to becoextruded into multi-layer webs. In addition, the vane die alsoprovides the ability to tailor the width of individual manifolds, suchthat an internal layer can be completely surrounded by the outer layerleaving no exposed edges. The aforementioned patents also disclose thecombined use of feedblock systems and vane dies to achieve more complexmultilayer structures.

[0073] One of skill in the art will recognize that the size of anextruder used to produce the webs of the present invention depends onthe desired production rate and that several sizes of extruders may beused. Suitable examples include extruders having a 1 (2.5 cm) to 1.5inch (3.7 cm) diameter with a length/diameter ratio of 24 or 30. Ifrequired by greater production demands, the extruder diameter can rangeupwards. For example, extruders having a diameter between about 2.5inches (6.4 cm) and about 4 inches (10 cm) can be used to produce thewebs of the present invention. A general purpose screw may be used. Asuitable feedblock is a single temperature zone, fixed plate block. Thedistribution plate is machined to provide specific layer thicknesses.For example, for a three layer web, the plate provides layers in an80/10/10 thickness arrangement, a suitable die is a single temperaturezone flat die with “flex-lip” die gap adjustment. The die gap istypically adjusted to be less than 0.020 inches (0.5 mm) and eachsegment is adjusted to provide for uniform thickness across the web. Anysize die may be used as production needs may require, however, 10-14inch (25-35 cm) dies have been found to be suitable. The chill roll istypically water-cooled. Edge pinning is generally used and occasionallyan air knife may be employed.

[0074] For some coextruded webs, the placement of a tacky hydrophilicmaterial onto the chill roll may be necessary. When the arrangementplaces the tacky material onto the chill roll, release paper may be fedbetween the die and the chill roll to minimize contact of the tackymaterial with the rolls. However, a preferred arrangement is to extrudethe tacky material on the side away from the chill roll. Thisarrangement generally avoids sticking material onto the chill roll. Anextra stripping roll placed above the chill roll may also assist theremoval of tacky material and also can provide for additional residencetime on the chill roll to assist cooling the web.

[0075] Occasionally, tacky material may stick to downstream rolls. Thisproblem may be minimized by either placing a low layer energy (e.g.Teflon®) sleeve on the affected rolls, wrapping Teflon tape on theeffected rolls, or by feeding release paper in front of the effectedrolls. Finally, if it appears that the tacky material may block toitself on the wound roll, release paper may be added immediately priorto winding. This is a standard method of preventing blocking of webduring storage on wound rolls. Processing aids, release agents orcontaminants should be minimized. In some cases, these additives canbloom to the layer and reduce the layer energy (raise the contact angle)of the hydrophilic layer.

[0076] An alternative method of making the multi-layer webs of thepresent invention is to extrude a web comprising a material suitable forone of the individual layers. Extrusion methods as may be known to theart for forming flat webs are suitable. Such webs may then be laminatedto form a multi-layer web suitable for formation into a fluid perviousweb using the methods discussed below. As will be recognized, a suitablematerial, such as a hot melt adhesive, can be used to join the webs toform the multi-layer web. A preferred adhesive is a pressure sensitivehot melt adhesive such as a linear styrene isoprene styrene (“SIS”)hotmelt adhesive, but it is anticipated that other adhesives, such aspolyester of polyamide powdered adhesives, hotmelt adhesives with acompatibilizer such as polyester, polyamide or low residual monomerpolyurethanes, other hotmelt adhesives, or other pressure sensitiveadhesives could be utilized in making the multi-layer webs of thepresent invention. Alternative methods of joining the webs to form themulti-layer web include, but are not limited to, ultrasonic bonding,thermal bonding, or any other suitable means as are known in the art.

[0077] In another alternative method of making the multi-layer formedweb plies of the present invention, a base or carrier web can beseparately extruded and one or more layers can be extruded thereon usingan extrusion coating process to form a multi-layer formed web plyaccording to the present invention. Preferably, the carrier web passesunder an extrusion die at a speed that is coordinated with the extruderspeed so as to form a very thin web having a thickness of less thanabout 25 microns. The molten polymer and the carrier web are broughtinto intimate contact as the molten polymer cools and bonds with thecarrier web. As noted above, a tie layer may enhance bonding between thelayers. A tie layer is typically comprised of a thermoplastic materialthat is able to bond with both adjacent layers. Tie layers are joined toadjacent layers using bonding means including, but not limited to,chemical bonds, physical entanglement of thermoplastic chains, andcombinations thereof. Contact and bonding are also normally enhanced bypassing the layers through a nip formed between two rolls. The bondingmay be further enhanced by subjecting the layer of the carrier web thatis to contact the web to layer treatment, such as corona treatment, asis known in the art and described in Modern Plastics EncyclopediaHandbook, p. 236 (1994), which is hereby incorporated by reference.

[0078] The thermoplastic formed web can be provided with substantiallythree dimensional surface structures using any process known in the art.Providing the web with three dimensional surface structures will providethe exterior surfaces of the web with a softer, more cloth-like texture,provide the web with a more cloth-like appearance, and increase theoverall caliper of the web. Examples of three dimensional surfacestructures processes include but are not limited to the following:hydroforming, vacuum forming, needle punching (solid or hollow),mechanical embossing, flocking, ultrasonics, delamination of viscousmelts from porous surfaces, printed hair, brushing, and any combinationthereof.

[0079] In a preferred embodiment, three dimensional surface structurescomprising microapertures are formed by applying a high pressure fluidjet comprised of water or the like against one surface of the formed webply, preferably while applying a vacuum adjacent the opposite surface ofthe formed web ply. In general, the formed web ply is supported on onelayer of a forming structure having opposed layers. The formingstructure is provided with a multiplicity of apertures there throughwhich place the opposed layers in fluid communication with one another.While the forming structure may be stationary or moving, a preferredembodiment uses the forming structure as part of a continuous processwhere the formed web ply has a direction of travel and the formingstructure carries formed web ply in the direction of travel whilesupporting the web. The fluid jet and, preferably, the vacuum cooperateto provide a fluid pressure differential across the thickness of the webcausing the web to be urged into conformity with the forming structureand to rupture in areas that coincide with the apertures in the formingstructure.

[0080] Such methods of aperturing are known as “hydroformation” and aredescribed in greater detail in commonly assigned U.S. Pat. No. 4,609,518issued to Curro, et al. on Sept. 2, 1986; U.S. Pat. No. 4,629,643 issuedto Curro, et al. on Dec. 16, 1986; U.S. Pat. No. 4,637,819 issued toOuellette, et al. on Jan. 20, 1987; U.S. Pat. No. 4,681,793 issued toLinman, et al. on Jul. 21, 1987; U.S. Pat. No. 4,695,422 issued toCurro, et al. on Sept. 22, 1987; U.S. Pat. No. 4,778,644 issued toCurro, et al. on Oct. 18, 1988; U.S. Pat. No. 4,839,216 issued to Curro,et al. on Jun. 13, 1989; and U.S. Pat. No. 4,846,821 issued to Lyons, etal. on Jul. 11, 1989, the disclosures of each of said patents beingincorporated herein by reference.

[0081] As mentioned above, the surface treated web of the presentinvention may also be formed by methods such as vacuum formation,mechanical methods such as punching, mechanical embossing, flocking,hydrosonics, ultrasonics, delamination of viscous melts or optionallydelamination of viscous melts from porous surfaces, printed hair, andbrushing.

[0082] Vacuum formation is disclosed in U.S. Pat. No. 4,463,045, issuedto Ahr, et al. on Jul. 31, 1984, the disclosure of which is herebyincorporated herein by reference.

[0083] Examples of mechanical methods are disclosed in U.S. Pat. No.4,798,604, issued to Carter on Jan. 17, 1989, U.S. Pat. No. 4,780,352,issued to Palumbo on Oct. 25, 1988, U.S. Pat. No. 3,566,726, issued toPolitis on Mar. 2, 1971, U.S. Pat. No. 4,634,440, issued to Widlund, etal. on Jan. 6, 1987, PCT Publication WO 97/40793, issued to Johansson,et al. on Nov. 6, 1997, and European Patent 525,676, issued to Dabi, etal., the disclosures of each of said patents being incorporated hereinby reference.

[0084] Examples of mechanical embossing are disclosed in EuropeanPatents 862,904, issued to Hisashi, et al. on Sep. 9, 1998, 858,792,issued to Tsuji, et al. on Aug. 19, 1998, Japanese Patents 8-260,329,issued to Wataru, et al., 10-131,014, issued to Wataru, et al., and U.S.Pat. No. 5,916,661, issued to Benson, et al. on Jun. 29, 1999, U.S. Pat.No. 5,628,097, issued to Benson, et al. on May 13, 1997, the disclosuresof each of said patents being incorporated herein by reference.

[0085] Examples of flocking are disclosed in PCT Publications WO98/42289, issued to Chen, et al. on Oct. 1, 1998, WO 98/36721, issued toJohansson, et al. on Aug. 27, 1998, and European Patent 861,646, issuedto Takai, et al. on Sep. 2, 1998, the disclosures of each of saidpatents being incorporated herein by reference.

[0086] Examples of ultrasonics are disclosed in U.S. Pat. No. 5,269,981,issued to Jameson, et al. on Dec. 14, 1993, the disclosure of which ishereby incorporated herein by reference.

[0087] Examples of delamination of viscous melts are disclosed in U.S.Pat. No. 3,967,623, issued to Butterworth et al. on Jul. 6, 1976.Examples of delamination of viscous melts from porous surfaces aredisclosed in PCT Publication WO 99/06623, issued to Calhoun, et al. onFeb. 11, 1999. Both disclosures of which are hereby incorporated hereinby reference.

[0088] Examples of printed hair are disclosed in U.S. Pat. No.5,670,110, issued to Dirk, et al. on Sep. 23, 1997, the disclosure ofwhich is hereby incorporated herein by reference.

[0089] Examples of brushing are disclosed in PCT Publication WO99/06623, issued to Calhoun, et al. on Feb. 11, 1999, the disclosure ofwhich is hereby incorporated herein by reference.

[0090] The polymeric film web can be provided with fluid transportapertures using any processes known in the art. Aperturing the web willincrease the fluid handling properties of the web and provide the webwith a more cloth-like, fiber-like appearance. Examples of suchprocesses include but are not limited to the following: mechanicalembossing, stretch rupturing, vacuum forming, hydroforming,hydrocutting, needle punching (solid or hollow), ultrasonics, slitting,ring-rolling, structural elastic-like web, and any combination thereof.

[0091] In a preferred embodiment, the fluid transport apertures areprovided to the web by mechanically embossing and stretch rupturing theweb material. Examples of mechanical embossing are disclosed above.Examples of stretch rupturing are disclosed in PCT Publication WO97/31601, issued to Hansson on Sep. 4, 1997, and the Benson patentslisted above. The disclosures of each of said patents are incorporatedherein by reference with respect to aperturing also.

[0092] Methods for vacuum formation, hydroforming, needle punching, andultrasonics are described above. The disclosures of each of said patentsare incorporated herein by reference with respect to aperturing also.With respect to ultrasonics, additional methods are disclosed in U.S.Pat. No. 5,879,494, issued to Hoff, et al. on Mar. 9, 1999, U.S. Pat.No. 5,269,981, issued to Jameson, et al. on Dec. 14, 1993, and EuropeanPatent 5,355,579, issued to Jameson, et al. on Apr. 7, 1993. Thedisclosures of each of said patents are incorporated herein byreference.

[0093] Methods of hydrocutting are disclosed in U.S. Pat. No. 5,567,736,issued to Turi, et al. on Oct. 22, 1996, and U.S. Pat. No. 5,770,144,issued to James, et al. on Jun. 23, 1998. The disclosures of each ofsaid patents are incorporated herein by reference.

[0094] Suitable slitting methods are disclosed in PCT Publication WO97/31601, issued to Hansson on Sep. 4, 1997, the disclosure of which ishereby incorporated herein by reference.

[0095] Suitable processes for ring rolling or “pre-corrugating” aredescribed in U.S. Pat. No. 4,107,364 issued to Sisson on Aug. 15, 1978,U.S. Pat. No. 4,834,741 issued to Sabee on May 30, 1989, U.S. Pat. No.5,167,897 issued to Weber et al. on Dec. 1, 1992, U.S. Pat. No.5,156,793 issued to Buell et al. on Oct. 20, 1992, and U.S. Pat. No.5,143,679 issued to Weber on Sep. 1, 1992. The disclosures of which areincorporated by reference.

[0096] Suitable methods of SELF-ing are described in U.S. Pat. No.5,518,801 issued to Chappell et al. on May 21, 1996. The disclosure ofwhich is incorporated by reference.

Absorbent Articles According to the Present Invention

[0097] As used herein, the term “absorbent article” refers to deviceswhich absorb and contain body exudates, and, more specifically, refersto devices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term “disposable” is used herein to describe absorbentarticles which are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use, and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” absorbent article refers to absorbent articles which areformed of separate parts united together to form a coordinated entity sothat they do not require separate manipulative parts like a separateholder and pad. Examples of absorbent articles that incorporate theapertured polymeric film web and the multi-ply composite structure ofthe present invention include disposable articles including sanitarynapkins, pantiliners, and diapers as described in pending U.S.application Ser. No. 09/344,161 filed by Lee, et al. on Jun. 24, 1999,the disclosure of which is hereby incorporated herein by reference.

Test Methods Softness Index Panel Softness Overview

[0098] A Descriptive Analysis Panel of trained graders is used tocompare the tactile softness, defined as fluffy, of a series of testproducts or topsheet materials. As used herein, fluffy is the attributethat describes the sensation of the nerve endings in the fingertips asthey are stimulated by lightly stroking a sample. The feel of 100%cotton flannel represents an extremely soft, fluffy material.

Graders

[0099] Graders are all female and are selected and trained for theirability to discriminate small differences in tactile softness. As partof this training, each grader identifies a “dominant” (i.e. mostsensitive) hand which is used in all evaluations. Graders are monitoredon a study to study basis and retrained as needed to minimize drift withtime.

Grading and Calibration

[0100] When the topsheet of sanitary pads are evaluated, the pads arelaid flat on the hard countertop surface with the topsheet facing up.When topsheet-only evaluations are performed, a felt sublayer is used tosimulate the core. A suitable material is 54 Polyester felt, RainbowClassic, Royal Blue as is available from Kunin Felt of Hampton, N.H.Other sublayers may give different sensory outcomes.

[0101] Graders use the first three fingertips of their dominant handarched in an upright position so only the fingertips contact the surfaceof the test sample. Graders use a floating stroke back and forth (5cycles) across the entire length of the topsheet surface of the testsample. Graders grasp the edge of the test sample with theirnon-dominant hand using the thumb, forefinger and middle finger flatlyagainst the counter surface to hold the sample in place. Graders aretrained and calibrated on reference samples which provide a commonsensory experience and demonstrate differences in the range of intensityfor fluffiness. Relative intensities are indicated on a 6 inch, 0 to 60,line scale where 0 is defined as not fluffy at all and 60 is identifiedas very fluffy.

[0102] The scale is calibrated with two commercially available sanitarynapkin products: Procter and Gamble's Always Ultra with Dri-weave (avacuum-formed film topsheet) is defined as having a fluffiness score of“10” and Kao's Laurier Soft Mesh Slim Regular (with a nonwoven topsheet)is defined as a “50” on the fluffiness scale.

Apparatus

[0103] The room designed for sensory evaluations has individual boothsfor grader separation. The booths have visual barriers that prevent thegraders from seeing samples during evaluations.

Method

[0104] Up to six test samples may be evaluated in any one test period.Samples are presented to each grader in a random order. All samples aremarked for direction prior to presentation so all graders evaluate thesamples in the same direction. When topsheet-only samples are evaluated,the sample is first spread smoothly on the felt before presentation tothe grader. Each sample is only graded one time. The grader grades eachsample using the 60 point scale for softness by marking the grade on alinear scale. A minimum of 12 graders evaluate each sample.

Report

[0105] The average and standard deviation are calculated for each sampletested. Outliers are excluded if they are more than two times thestandard deviation away from the average. The “softness index” is theaverage for each sample excluding any outliers. Known methods ofdetermining statistically significant differences (e.g. analysis ofvariance, Newman-Keuls Multiple Range Test, etc.) may be used.

Compressibility Index Caliper vs. Z-compression Protocol

[0106] A. Materials:

[0107] 1. Strain gauge (e.g. Ames Co. mechanical caliper gauge (JeweledShockless Model #482 Walthan, Mass., USA) capable of measuring to thenearest 0.001 inch and using a foot with area between 1-2 in².

[0108] 2. Sample with dimensions or area larger than the area of thefoot.

[0109] B. Protocol:

[0110] 1. Place sample under the foot of the strain gauge so that a.)there are no wrinkles or creases in the sample, and b.) the sample edgesextend beyond the edges of the foot. All measurements taken at 73° F.

[0111] 2. Lower the foot to achieve a pressure of 0.06 psi.

[0112] 3. Wait 10 seconds and then record caliper to the nearest 0.001inch.

[0113] 4. Add weight immediately after recording caliper to obtain apressure of 0.1 psi.

[0114] 5. Repeat steps 3 & 4, except add the weight sufficient to obtainpressures of 0.2, 0.5, 0.75 & 1.0 psi.

[0115] 6. Repeat steps 1 through 5 for 3 additional sections on the samesample or 3 new samples, do not re-test any of the sections.

Calculations

[0116] 1. Calculate the “compressibility” for each sample, as usedherein, is the % compression at 0.2 psi, by the following equation:

“Compressibility”=[(L ₀ −L)/L ₀]×100

[0117] L₀=caliper at 0.06 psi

[0118] L=caliper at 0.2 psi

[0119] Calculate the “compressibility index” by averaging the“compressibility” of the four samples.

Test Results

[0120] As can be seen in the Table below, representative aperturedpolymeric film webs of the present invention are both softer and morecompressible than those of prior art. DRI-WEAVE has a particularlyplastic-feeling top surface and is not easily compressed. The doublyhydroforned prior art film, while it has much better tactile feel andcompressibility, is still not nearly as soft, silky and cloth-like asthe webs of the present invention. Thus, the surprising combination ofthree dimensional surface structures and fluid transport apertures canprovide polymeric film webs with aesthetics similar to nonwovens withoutthe undesirable fluid retaining capillary network common to nonwovens.Compressibility Softness Index Index Topsheet (panel score unit) (%)Prior art vacuum formed film (1)  6 10 Prior art doubly hydroformed film(2) 33 22 EXAMPLE 2 of present invention 47 44 EXAMPLE 3 of presentinvention 41 41

EXAMPLES Web Preparation Example

[0121] An extruded trilayer polymeric film web should be prepared inaccordance with pending U.S. application Ser. No. 09/344,161 filed byLee, et al. on Jun. 24, 1999, the disclosure of which is herebyincorporated herein by reference. Other embodiments of the presentinvention include webs extruded with materials exhibiting varyingcharacteristics as described above (i.e., philic/philic, phobic, philic,surface energy gradient, permeability, etc.).

Web Processing Examples

[0122] The following examples demonstrate the processing of a polymericfilm web to provide the web with three dimensional surface structuresand fluid transport apertures. The following examples have permanenthydrophilicity according to a preferred embodiment of the presentinvention. Other embodiments of the present invention webs with varyingcharacteristics.

Example 1

[0123] A. Three Dimensional Surface Structure Process

[0124] The extruded trilayer web comprising a polyethylene layer, aBynel® 3860 layer and a 50/50 Hytrel® HTR 8171/Hytrel® HTR 8206 layer(80/10/10 layer weight ratio) described above is hydroformed on a100-mesh screen with holes approximately 7 mil in diameter, under awater pressure of approximately 1,000 pounds per square inch (psi), at atemperature of 160° Fahrenheit (F.), and at a rate of 20 fpm.

[0125] The three dimensional surface structures made in this way arecone-shaped microapertures with dimensions of approximately 3-7 mildiameter and 5-7 mil height.

[0126] B. Fluid Transport Aperturing Process

[0127] The hydroformed web from A. above is fed through the “weakeningroller arrangement” (see U.S. Pat. No. 5,628,097—FIGS. 2&3, which isincorporated herein by reference) preferably comprising a patternedcalendar roller and the smooth anvil roller. One or both of the rollersmay be heated. Pressure between the two rollers may be adjusted toweaken and melt-stabilize the web at a plurality of locations. The webis then passed through a nip formed by the incremental stretching systememploying opposed pressure applicators having three-dimensional surfaceswhich at least to a degree are complimentary to one-another. Theincrementally stretching roller has a plurality of teeth andcorresponding grooves which extend about the entire circumference of theroller. The web is subjected to tensioning in the CD to cause theweakened melt-stabilized locations to rupture, creating a plurality ofapertures coincident with the weakened melt stabilized locations in theweb.

Example 2

[0128] A. Three Dimensional Surface Structure Process and FluidTransport Aperturing Process

[0129] A polymeric film made of polyethylene (1.05 mil thick, 50/50 lowdensity polyethylene/linear low density polyethylene) was processed forboth steps A & B as in Example 1 above.

Example 3

[0130] A. Three Dimensional Surface Structure Process

[0131] A polymeric film made of polyethylene (1.05 mil thick, 50/50 lowdensity polyethylene/linear low density polyethylene) was hydroformedand apertured as in Example 1 above.

[0132] B. Fluid Transport Aperturing Process

[0133] 100 Mesh hydroformed film was placed between the mutuallyengagable male/female plates (PGP Herringbone #87, Harrington ProductDevelopment Center, Cincinnati, Ohio). Mutually engagable plate assemblycontaining material was loaded into a hydraulic press (e.g. Hydraulicpress, Model #6277/93, Scott Industrial Systems Co., Dayton, Ohio).SELFing (SELF: Structural Elastic-Like Film, as taught in U.S. Pat. No.5,518,801) was then performed by engaging male and female plate until apressure of 400 psi is reached for approximately 2 seconds.

Example 4

[0134] A. Three Dimensional Surface Structure Process

[0135] A thermoplastic web as described above is abraded as described inExamples 1-4 of PCT Publication WO 99/06623 as cited above to create afibrillated surface.

[0136] B. Fluid Transport Aperturing Process

[0137] The web from A. above is apertured as in Example 1. B. above.

Example 5

[0138] A. Three Dimensional Surface Structure Process

[0139] A thermoplastic hydroformed web from Example 1. A. above issubjected to an abrasion step as described in PCT Publication WO99/06623 as cited above.

[0140] B. Fluid Transport Aperturing Process

[0141] The web from A. above is apertured using needles according to PCTPublication WO 98/36721 as cited above.

[0142] The steps delineated in the above examples may be performed inany order and combination excluding those that are described in theprior art.

[0143] As mentioned above, the apertured polymeric film webs describedin Examples 1-5 above may also be placed adjacent or joined to a sub-plyto form a multi-ply composite structure. In creating such a structure,the ply may be apertured separately prior to forming the structure orapertured simultaneously to create common fluid communication pathwaysbetween the ply.

[0144] The disclosures of all patents, patent applications (and anypatents which issue thereon, as well as any corresponding publishedforeign patent applications), and publications mentioned throughout thisdescription are hereby incorporated by reference herein. It is expresslynot admitted, however, that any of the documents incorporated byreference herein teach or disclose the present invention.

[0145] While various embodiments and/or individual features of thepresent invention have been illustrated and described, it would beobvious to those skilled in the art that various other changes andmodifications can be made without departing from the spirit and scope ofthe invention. As will be also be apparent to the skilled practitioner,all combinations of the embodiments and features taught in the foregoingdisclosure are possible and can result in preferred executions of theinvention. It is therefore intended to cover in the appended claims allsuch changes and modifications that are within the scope of thisinvention.

What is claimed is:
 1. An apertured polymeric film web having multiplesurfaces and exhibiting a soft and silky tactile impression on at leastone of said surfaces, wherein: said polymeric film web is provided witha multiplicity of substantially three dimensional surface structures onat least one of said surfaces of said polymeric film web; said polymericfilm web is provided with a multiplicity of fluid transport aperturesthat place at least two of said surfaces in fluid communication with oneanother; and said polymeric film web has a softness index greater than35.
 2. An apertured polymeric film web having multiple surfaces andexhibiting a soft and silky tactile impression on at least one of saidsurfaces, wherein: said polymeric film web is provided with amultiplicity of substantially three dimensional surface structures on atleast one of said surfaces of said polymeric film web; said polymericfilm web is provided with a multiplicity of fluid transport aperturesthat place at least two of said surfaces in fluid communication with oneanother; and said polymeric film web has a compressibility index greaterthan 25 percent.
 3. The polymeric film web of claim 1, wherein saidthree dimensional surface structures are substantially unalteredrelative to their as-made state.
 4. The polymeric film web of claim 2,wherein said three dimensional surface structures are substantiallyunaltered relative to their as-made state.
 5. The polymeric film web ofclaim 1, said web further comprises a top surface and a bottom surface,wherein: said top surface and said bottom surface are comprised ofmaterials that provide a surface energy gradient between the surfaces.6. The polymeric film web of claim 2, said web further comprises a topsurface and a bottom surface, wherein: said top surface and said bottomsurface are comprised of materials that provide a surface energygradient between the surfaces.
 7. The polymeric film web of claim 1,said polymeric film web further comprising a thermoplastic formed filmply comprising at least a first layer and a second layer, wherein: saidfirst layer is less hydrophilic than said second layer; and said secondlayer is permanently hydrophilic.
 8. The polymeric film web of claim 2,said polymeric film web further comprising a thermoplastic formed filmply comprising at least a first layer and a second layer, wherein: saidfirst layer is less hydrophilic than said second layer; and said secondlayer is permanently hydrophilic.
 9. A method of making an aperturedpolymeric film web having a softness index greater than 35, the methodcomprising the steps of: a) providing at least one thermoplasticmaterial; b) melting each of said thermoplastic materials; c) passingsaid melted thermoplastic materials through extrusion die orifices toform individual layers of thermoplastic film; d) providing at least onesurface of said film with a multiplicity of substantially threedimensional surface structures; and e) providing said film with amultiplicity of fluid transport apertures.
 10. The method of making anapertured polymeric film web of claim 9, wherein step e is completedprior to step d.
 11. A method of making an apertured polymeric film webhaving a compressibility index greater than 25 percent, the methodcomprising the steps of: a) providing at least one thermoplasticmaterial; b) melting each of said thermoplastic materials; c) passingsaid melted thermoplastic materials through extrusion die orifices toform individual layers of thermoplastic film; d) providing at least onesurface of said film with a multiplicity of substantially threedimensional surface structures; and e) providing said film with amultiplicity of fluid transport apertures.
 12. The method of making anapertured polymeric film web of claim 11, wherein step e is completedprior to step d.
 13. A method of making an apertured polymeric film web,the method comprising the steps of: a) providing at least onethermoplastic material; b) melting each of said thermoplastic materials;c) passing said melted thermoplastic materials through extrusion dieorifices to form individual layers of thermoplastic film; d) providingat least one surface of said film with a multiplicity of substantiallythree dimensional surface structures using a process selected from thegroup consisting of vacuum forming, hydroforming, solid needle punching,hollow needle punching, ultrasonics, and hydrosonics; and e) providingsaid film with a multiplicity of fluid transport apertures using aprocess selected from the group consisting of mechanical embossing,stretch rupturing, vacuum forming, solid needle punching, hollow needlepunching, ultrasonics, hydrosonics, slitting, ring-rolling, formingstructural elastic like film, and sintering.
 14. The method of making anapertured polymeric film web in claim 13, wherein: said process forproviding at least one surface of said film with a multiplicity ofsubstantially three dimensional surface structures is selected from thegroup consisting of vacuum forming, solid needle punching, hollow needlepunching, ultrasonics, and hydrosonics; and said process for providingsaid film with a multiplicity of fluid transport apertures ishydroforming.
 15. The method of making an apertured polymeric film webof claim 13, wherein step e is completed prior to step d.
 16. The methodof making an apertured polymeric film web of claim 14, wherein step e iscompleted prior to step d.
 17. A multi-ply composite structure comprisedof a fluid permeable thermoplastic formed film ply having a body facingsurface and a garment facing surface and a fluid permeable sub-ply,wherein: said thermoplastic formed film ply is comprised of theapertured polymeric film web in claim 1; and said fluid permeablesub-ply is adjacent to said garment facing surface of said thermoplasticformed film ply.
 18. A multi-ply composite structure comprised of afluid permeable thermoplastic formed film ply having a body facingsurface and a garment facing surface and a fluid permeable sub-ply,wherein: said thermoplastic formed film ply is comprised of theapertured polymeric film web in claim 2; and said fluid permeablesub-ply is adjacent to said garment facing surface of said thermoplasticformed film ply.
 19. The multi-ply composite structure of claim 17, saidthermoplastic formed film ply further comprises: at least a top surfaceand a bottom surface, wherein said top surface and said bottom surfaceare comprised of materials that provide a surface energy gradientbetween the surfaces.
 20. The multi-ply composite structure of claim 18,said thermoplastic formed film ply further comprises: at least a topsurface and a bottom surface, wherein said top surface and said bottomsurface are comprised of materials that provide a surface energygradient between the surfaces.
 21. A multi-ply composite structurecomprised of a thermoplastic formed film ply having a body facingsurface and a garment facing surface and a sub-ply, wherein: said bodyfacing surface has a multiplicity of substantially three dimensionalsurface structures disposed thereon; said thermoplastic formed film plyis provided with fluid transport apertures to form an aperturedthermoplastic formed film ply; said sub-ply is provided with fluidtransport apertures and is adjacent to said garment facing surface ofsaid apertured thermoplastic formed film ply; and said fluid transportapertures form fluid pathways common to both of said ply.
 22. Themulti-ply composite structure of claim 21, wherein said sub-ply iscomprised of a fluid permeable material.
 23. The multi-ply compositestructure of claim 21, said apertured thermoplastic formed film plyfurther comprising: at least a top surface and a bottom surface, whereinsaid top surface and said bottom surface are comprised of materials thatprovide a surface energy gradient between the surfaces.
 24. A method ofmaking a multi-ply composite, the method comprising the steps of: a)providing a fluid permeable thermoplastic formed film ply havingmultiple surfaces with a multiplicity of substantially three dimensionalsurface structures on at least one of said surfaces; b) providing asub-ply having multiple surfaces; and c) feeding said fluid permeablethermoplastic formed film ply and said sub-ply simultaneously through anaperturing process to form an apertured multi-ply composite structurehaving fluid transport pathways common to both of said ply.
 25. Themethod of making a multi-ply composite structure in claim 24, whereinsaid sub-ply is comprised of a fluid permeable material.
 26. The methodof making a multi-ply composite structure in claim 24, wherein theaperturing process leaves said three dimensional surface structuressubstantially unaltered relative to their as-made state.
 27. The methodof making a multi-ply composite structure in claim 24, saidthermoplastic formed film ply further comprising: at least a top surfaceand a bottom surface, wherein said top surface and said bottom surfaceare comprised of materials that provide a surface energy gradientbetween the surfaces.
 28. The method of making a multi-ply compositestructure in claim 24, said thermoplastic formed film ply furthercomprising: at least a first layer and a second layer, wherein saidfirst layer is less hydrophilic than said second layer; and said secondlayer is permanently hydrophilic.
 29. A method of making a multi-plycomposite, the method comprising the steps of: a) providing a fluidpermeable thermoplastic formed film ply having multiple surfaces with amultiplicity of substantially three dimensional surface structures on atleast one of said surfaces; b) providing a fluid permeable sub-plyhaving multiple surfaces; and c) laying one surface of saidthermoplastic formed film ply adjacent to one surface of said sub-ply toform a multi-ply composite structure.
 30. The method of making amulti-ply composite structure in claim 29, said thermoplastic formedfilm ply further comprising: at least a top surface and a bottomsurface, wherein said top surface and said bottom surface are comprisedof materials that provide a surface energy gradient between thesurfaces.
 31. The method of making a multi-ply composite structure inclaim 29, said thermoplastic formed film ply further comprising: atleast a first layer and a second layer, wherein said first layer is lesshydrophilic than said second layer; and said second layer is permanentlyhydrophilic.
 32. The apertured polymeric film web of claim 1, whereinsaid web is suitable for use as a topsheet on an absorbent article andsaid article is disposable.
 33. The apertured polymeric film web ofclaim 1, wherein said web is suitable for use as a topsheet on anabsorbent article and said article is a sanitary napkin or a pantiliner.34. The apertured polymeric film web of claim 1, wherein said web issuitable for use as a topsheet on an absorbent article and said articleis a disposable diaper.
 35. The apertured polymeric film web of claim 1,wherein said web is suitable for use as a topsheet on an absorbentarticle and said article is a tampon.
 36. The apertured polymeric filmweb of claim 2, wherein said web is suitable for use as a topsheet on anabsorbent article and said article is disposable.
 37. The aperturedpolymeric film web of claim 2, wherein said web is suitable for use as atopsheet on an absorbent article and said article is a sanitary napkinor a pantiliner.
 38. The apertured polymeric film web of claim 2,wherein said web is suitable for use as a topsheet on an absorbentarticle and said article is a disposable diaper.
 39. The aperturedpolymeric film web of claim 2, wherein said web is suitable for use as atopsheet on an absorbent article and said article is a tampon.
 40. Themulti-ply composite structure of claim 17, wherein said structure issuitable for use in an absorbent article and said article is disposable.41. The multi-ply composite structure of claim 17, wherein saidstructure is suitable for use in an absorbent article and said articleis a sanitary napkin or a pantiliner.
 42. The multi-ply compositestructure of claim 17, wherein said structure is suitable for use in anabsorbent article and said article is a disposable diaper.
 43. Themulti-ply composite structure of claim 17, wherein said structure issuitable for use in an absorbent article and said article is a tampon.44. The multi-ply composite structure of claim 18, wherein saidstructure is suitable for use in an absorbent article and said articleis disposable.
 45. The multi-ply composite structure of claim 18,wherein said structure is suitable for use in an absorbent article andsaid article is a sanitary napkin or a pantiliner.
 46. The multi-plycomposite structure of claim 18, wherein said structure is suitable foruse in an absorbent article and said article is a disposable diaper. 47.The multi-ply composite structure of claim 18, wherein said structure issuitable for use in an absorbent article and said article is a tampon.48. The multi-ply composite structure of claim 21, wherein saidstructure is suitable for use in an absorbent article and said articleis disposable.
 49. The multi-ply composite structure of claim 21,wherein said structure is suitable for use in an absorbent article andsaid article is a sanitary napkin or a pantiliner.
 50. The multi-plycomposite structure of claim 21, wherein said structure is suitable foruse in an absorbent article and said article is a disposable diaper. 51.The multi-ply composite structure of claim 21, wherein said structure issuitable for use in an absorbent article and said article is a tampon.